POLYETHYLENE

PLASTIC PIPE
PLASTIC MANUFACTURES SINCE 1953

FUSION

BUTT

TECHNIQUE

Technical Note

BUTT FUSION TECHNIQUE

Disclaimer
The information contained in this technical note is intended to serve as a general guideline for fusion conditions. This technical note is not intended to serve as an installation procedure. In general, specific fusion parameters will have to be developed and verified to accommodate for changes in prevailing ambient conditions and specific field conditions. Polytubes position is that all personnel performing field fusion operations, be certified by A. H. McElroys fusion school, so that they understand how to develop field specific fusion conditions and so that they understand how to validate those conditions. Polytubes accepts no liability for any injury or damage associated with the misuse of this information or any improperly performed fusion operations.

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Technical Note
Butt Fusion Parameters
Polytubes *High Density Piping Systems are joined together by the Butt Fusion Joining Method. Shown in Figure 1 is an illustration of the BUTT FUSION Technique.

FIGURE 1
Schematic of the Butt Fusion Technique

PF = t1 = t2 = t3 = t4 = t5 =

Interfacial pressure level. Initial heating, joining and cooling (Determined by Bead Formation size) Bead formation, heating time under pressure Heat soak time under reduced pressure Removal of heating device Bead formation time under pressure Cooling time under a constant pressure

Note:*Testing has shown that the parameters stated in this Technical Bulletin can be used successfully for the following High Density Polyethylene (HDPE) materials; PE-3408 (Novas HD-2007-H) PE-3408 (Dows DGDC-2480) PE-100 (Dows DGDA-2490) A certified fusion technician possesses the appropriate training required for a proper Butt Fusion Joint as shown in Figure II.

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Technical Note
This technique involves the contact of two ends of pipe or pipe fittings with heat to soften the polyethylene, forming a MOLTEN BEAD around the circumference. After the recommended HEAT CYCLE has been reached (see Chart 1 - Fusion Joint Heating Time - @ 23C) the two ends are brought together slowly and pressure is applied so that the pipe ends are literally fused together molecularly.

Chart I HDPE Fusion Joint Heating Time

40 35
Wall Thickness (mm)

30 25 20 15 10 5 0 0 50 100 150 200 250

Time (seconds)

Series2

Notes: 1. It is imperative that the heater plate surface be thoroughly cleaned before and after each joint is made. 2. The heating time as it relates to wall thickness is a guideline for warm ambient conditions (@ 23C). This parameter needs to be adjusted for environmental conditions and validated with fusion testing. 3. The temperature of the heater plates must be checked before every fusion with a pyrometer or a infrared pyrometer. Temperatures may have to be adjusted upwards depending on ambient conditions. Polytubes recommended temperature is 218C - 230 C (425F - 450F) for coated heating plates. 4. Heating time starts after the bead of molten material is first visible around the complete circumference of both pipe ends. 5. The dwell times recommended for joining are approximate. Actual length of time will vary with ambient conditions. Contact your Polytubes representative for dwell times at colder conditions. It is extremely important that the correct melt bead size be formed during the heating cycle. Refer to Chart 3 for approximate melt bead sizes that should be obtained during the heating cycle. Heating

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Technical Note
cycle times and interfacial pressure shall be adjusted in order to ensure that the correct melt bead will form. The fused joint while under pressure is then allowed to cool as shown in (Chart 2) Minimum Fusion Joint Cooling Time. This will ensure the bead formation has solidified prior to removal from the fusion machine. It is essential to allow the joint to cool slowly at ambient conditions, permitting crystallinity to reform in the HAZ (Heat Affected Zone) area.

CHART 2 Minimum FUSION Joint Cooling Time Wall Thickness as a Function of Time
25

20

W Thickness (mm) all

15

10

0 0 5 10 15 20

Time (minutes)

Note: 1. The dwell times recommended for cooling are approximate. Actual length of time will vary with ambient conditions. Allow additional time before bending, stressing or destructive testing the fusion joint. It is extremely important that the correct finished bead size be formed after the cooling cycle is complete. Interfacial pressure can vary with equipment. The Interfacial pressure should be modified to attain the Finished bead formation shown in Figure I.

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Technical Note
With the variety of butt fusion equipment available to join H.D.P.E. pipe, the following formula can be applied to obtain the correct gauge pressure readings that provide the desired interfacial pressure.

A PG = x x Pi Ae
Where: Pg = Ax = Ae = Pi = Gauge pressure reading Cross-sectional area of pipe wall Effective cross sectional area of the hydraulic cylinder(s) Interfacial pressure as recommended

INTERFACIAL PRESSURE (CALCULATED OVER THE ENTIRE WELDING SURFACE): During bead formation: During heat soak cycle During joining and cooling 50 - 75 psi zero 50 - 75 psi (0.34 - 0.52 Mpa) zero (0.34 - 0.52 Mpa)

EXAMPLE: For 8 SDR 17 (Series 100 pipe) O.D. = 8.625 inches I.D. = 7.610 inches Wall (t) = 0.507 inches Pipe Area = 12.94 sq inches

OD 2 ID2 Ax =
4

3.1416 =

8.6252 7.610 2
4

12.94

in

Ae = 6.01 in2

(Note: refer to machine manufacturer for Ae value of each different model)

Fusion

Pg =

12.94 x 75 6.01

161.4 psi

Note: Pressure to overcome drag forces on the fusion machine and along the pipe length must be determined prior to each joint. This value must be added to the Pg value from above. Multiply by 0.0689 for conversion of psi to bars (kgs/cm2).

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Technical Note
ILLUSTRATION OF A PROPERLY MADE BUTT FUSION JOINT
FIGURE II

Fusion Environment
Just to mention a few, extreme windy and cold conditions will alter the heat and cooling times for the fusion procedure. Consideration has to be given to ensure that the fusion times and procedures compensate for these conditions to produce a sturdy fusion joint. If joint integrity is questionable, a new joint must be made and the questionable joint must be qualified by a Bend Back test, to validate the fusion parameters. Please contact your Fusion instructor for procedure and testing details. Excessive moisture (rain, snow or humidity) is another factor that could alter you fusion conditions.

Considerations: WindyConditions: The pipe and heating plate should not be exposed to wind or temperature
variations may occur. It is recommended that shelters should be used to protect the pipe and fusion plate to ensure the fusion conditions can be in a more consistent environment.

Cold Conditions: In cold weather, heating periods will be longer due to the initial temperature of
the pipe. Conducting fusions joints at temperatures below -10C special considerations has to be given to modifying the working conditions, for example using a tent with a warm air environment. Working at temperatures below 0C the pipe ends need to be warmed up using a heater blanket to

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Technical Note
elevate the pipe temperature to a maximum of 40C (using a pyrometer to measure) will improve the heat cycle starting condition. Oxidizing devices such as Tiger Torches shall not be used to pre heat the pipe.

Data Logging:
All fusion joints must be data-logged. Electronic data-logging is preferred (and generally expected when hydraulic equipment is used) but is not always possible and therefore a manual log can be acceptable. Parameters that need to be recorded at minimum are as follows: o Date, Time o Technician, Equipment type, and unit # o Fusion # ( which also must be permanently marked on pipe at joint) o Ambient temperature, Preheat Time o Iron Temperature, Heat Soak Time o Drag Pressure, Hydraulic Pressure, Total Fusion Pressure o Cooling Time The data record must be kept for the lifetime of the pipeline.

See example of manual Data Logging information required attached in this brochure.

Installation
Polytubes (High Molecular Weight) High Density Polyethylene Pipe is intended for professional installation. Experience with proper butt and socket fusion techniques is recommended. For complete design and installation information, contact your POLYTUBES representative:

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Technical Note
Example Fusion Calculation

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